Turbomachine thrust balancing system

ABSTRACT

An example turbomachine thrust balancing system includes a member coupled in rotation with a turbine for transferring rotational power therefrom. A load carrying device rotatably supports the member. The load carrying device is configured to counteract substantially all of the thrust load generated by the turbine.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 61/705,708, which was filed on 26 Sep. 2012 and is incorporated herein by reference.

BACKGROUND

This disclosure relates generally to thrust loads within a turbomachine and, more particularly, to balancing thrust loads to mitigate damage to various turbomachine components.

Turbomachines, such as gas turbine engines, typically include a fan section, a compression section, a combustor section, and a turbine section. Turbomachines may employ a geared architecture connecting portions of the compression section to the fan section.

The geared architecture may be an epicyclical gear assembly that causes the fan section and the turbine section to rotate at different speeds, which can increase overall propulsive efficiency. Typically, a shaft driven by one of the turbine sections provides an input to the epicyclical gear assembly that drives the fan section at the reduced speed. Because the turbine drives the fan through the geared architecture, the turbine and the fan are decoupled from one another such that thrust loads associated with the fan do not counteract thrust loads associated with the turbine.

Direct drive gas turbine engine configurations, by contrast, include turbine sections coupled to the fan section through a common shaft. In direct drive gas turbine engines, the fan and turbine sections provide counteracting thrust forces through the common shaft.

SUMMARY

An exemplary turbomachine thrust balancing system according to an exemplary aspect of the present disclosure includes, among other things, a member coupled in rotation with a turbine for transferring rotational power therefrom. A load carrying device rotatably supports the member. The load carrying device is configured to counteract the thrust load generated by the turbine.

In a further non-limiting embodiment of the foregoing turbomachine thrust balancing system, the load carrying device may comprise ball bearings.

In a further non-limiting embodiment of either of the foregoing turbomachine thrust balancing systems, the ball bearings have a diameter that is 0.75 inches or greater.

In a further non-limiting embodiment of any of the foregoing turbomachine thrust balancing systems, the load carrying device may comprise tapered roller bearings.

In a further non-limiting embodiment of any of the foregoing turbomachine thrust balancing systems, the thrust load may be rearward relative to a direction of flow through the turbomachine.

In a further non-limiting embodiment of any of the foregoing turbomachine thrust balancing systems, the member may be rotatably coupled to a geared architecture of a turbomachine.

In a further non-limiting embodiment of any of the foregoing turbomachine thrust balancing systems, the member may be a fan drive shaft.

In a further non-limiting embodiment of any of the foregoing turbomachine thrust balancing systems, the load carrying device may be configured to counteract a thrust load of more than 30,000 pounds.

A turbomachine according to an exemplary aspect of the present disclosure includes, among other things, a fan including a plurality of fan blades rotatable about an axis, and a turbine section includes a fan drive turbine. A geared architecture is configured to be rotatably driven by a member that is rotatably driven by the fan drive turbine to rotate the fan about the axis. A load carrying device supports rotation of the member and counteracts the thrust loads generated by the fan drive turbine.

In a further non-limiting embodiment of the foregoing turbomachine, the load carrying device may comprise ball bearings.

In a further non-limiting embodiment of either of the foregoing turbomachines, the ball bearings have a diameter that is at least 0.75 inches.

In a further non-limiting embodiment of any of the foregoing turbomachines, the load carrying device may comprise tapered roller bearings.

In a further non-limiting embodiment of any of the foregoing turbomachines, the thrust load may be applied rearward relative to a direction of flow through the turbomachine.

In a further non-limiting embodiment of any of the foregoing turbomachines, the load carrying device may be configured to counteract a thrust load of more than 30,000 pounds.

In a further non-limiting embodiment of any of the foregoing turbomachines, a rear disk cavity has a pressure that is less than about 20 psi different than a pressure in a gas path of the turbomachine.

A method of balancing thrust loads within a turbomachine according to an exemplary aspect of the present disclosure includes, among other things, rotating a member with a turbine; supporting rotation of the member using a load carrying device, driving a geared architecture with the member, and counteracting thrust loads exerted on the member by the turbine using the load carrying device.

In a further non-limiting embodiment of the foregoing method of balancing thrust loads within a turbomachine, the method includes counteracting the thrust loads with ball bearings having a diameter that is greater than 0.75 inches.

In a further non-limiting embodiment of either of the foregoing methods of balancing thrust loads within a turbomachine, the method includes counteracting thrust loads greater than 30,000 pounds.

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of the disclosed examples will become apparent to those skilled in the art from the detailed description. The figures that accompany the detailed description can be briefly described as follows:

FIG. 1 shows a cross-section view of an example turbomachine.

FIG. 2 shows a partial section view of a load carrying device of the turbomachine of FIG. 1.

FIG. 3 shows a cross-section of the assembly of FIG. 2.

FIG. 4 shows a partial exploded view of a roller bearing assembly suitable for use with the turbomachine of FIG. 1.

FIG. 5 shows a section view of the assembly of FIG. 4 in an operating position.

DETAILED DESCRIPTION

FIG. 1 schematically illustrates an example gas turbine engine 20 that includes a fan section 22, a compressor section 24, a combustor section 26 and a turbine section 28. Alternative engines might include an augmenter section (not shown) among other systems or features. The fan section 22 drives air along a bypass flow path B while the compressor section 24 draws air in along a core flow path C where air is compressed and communicated to a combustor section 26. In the combustor section 26, air is mixed with fuel and ignited to generate a high pressure exhaust gas stream that expands through the turbine section 28 where energy is extracted and utilized to drive the fan section 22 and the compressor section 24.

Although the disclosed non-limiting embodiment depicts a turbofan gas turbine engine, it should be understood that the concepts described herein are not limited to use with turbofans as the teachings may be applied to other types of turbine engines; for example a turbine engine including a three-spool architecture in which three spools concentrically rotate about a common axis and where a low spool enables a low pressure turbine to drive a fan via a gearbox, an intermediate spool that enables an intermediate pressure turbine to drive a first compressor of the compressor section, and a high spool that enables a high pressure turbine to drive a high pressure compressor of the compressor section.

The example engine 20 generally includes a low speed spool 30 and a high speed spool 32 mounted for rotation about an engine central longitudinal axis A relative to an engine static structure 36 via several bearing systems 38. It should be understood that various bearing systems 38 at various locations may alternatively or additionally be provided.

The low speed spool 30 generally includes an inner shaft 40 that connects a fan 42 and a low pressure (or first) compressor section 44 to a low pressure (or first) turbine section 46. The inner shaft 40 drives the fan 42 through a speed change device, such as a geared architecture 48, to drive the fan 42 at a lower speed than the low speed spool 30. The high speed spool 32 includes an outer shaft 50 that interconnects a high pressure (or second) compressor section 52 and a high pressure (or second) turbine section 54. The inner shaft 40 and the outer shaft 50 are concentric and rotate via the bearing systems 38 about the engine central longitudinal axis A.

A combustor 56 is arranged between the high pressure compressor 52 and the high pressure turbine 54. In one example, the high pressure turbine 54 includes at least two stages to provide a double stage high pressure turbine 54. In another example, the high pressure turbine 54 includes only a single stage. As used herein, a “high pressure” compressor or turbine experiences a higher pressure than a corresponding “low pressure” compressor or turbine.

The example low pressure turbine 46 has a pressure ratio that is greater than about 5. The pressure ratio of the example low pressure turbine 46 is measured prior to an inlet of the low pressure turbine 46 as related to the pressure measured at the outlet of the low pressure turbine 46 prior to an exhaust nozzle.

A mid-turbine frame 58 of the engine static structure 36 is arranged generally between the high pressure turbine 54 and the low pressure turbine 46. The mid turbine frame 58 further supports bearing systems 38 in the turbine section 28 as well as setting airflow entering the low pressure turbine 46.

The core airflow C is compressed by the low pressure compressor 44 then by the high pressure compressor 52 mixed with fuel and ignited in the combustor 56 to produce high speed exhaust gases that are then expanded through the high pressure turbine 54 and low pressure turbine 46. The mid-turbine frame 58 includes vanes 60, which are in the core airflow path and function as an inlet guide vane for the low pressure turbine 46. Utilizing the vane 60 of the mid-turbine frame 58 as the inlet guide vane for low pressure turbine 46 decreases the length of the low pressure turbine 46 without increasing the axial length of the mid-turbine frame 58. Reducing or eliminating the number of vanes in the low pressure turbine 46 shortens the axial length of the turbine section 28. Thus, the compactness of the gas turbine engine 20 is increased and a higher power density may be achieved.

The disclosed gas turbine engine 20 in one example is a high-bypass geared aircraft engine. In a further example, the gas turbine engine 20 includes a bypass ratio greater than about six (6), with an example embodiment being greater than about ten (10). The example geared architecture 48 is an epicyclical gear train, such as a planetary gear system, star gear system or other known gear system, with a gear reduction ratio of greater than about 2.3.

In one disclosed embodiment, the gas turbine engine 20 includes a bypass ratio greater than about ten (10:1) and the fan diameter is significantly larger than an outer diameter of the low pressure compressor 44. It should be understood, however, that the above parameters are only exemplary of one embodiment of a gas turbine engine including a geared architecture and that the present disclosure is applicable to other gas turbine engines.

A significant amount of thrust is provided by the bypass flow B due to the high bypass ratio. The fan section 22 of the engine 20 is designed for a particular flight condition—typically cruise at about 0.8 Mach and about 35,000 feet. The flight condition of 0.8 Mach and 35,000 ft., with the engine at its best fuel consumption—also known as “bucket cruise Thrust Specific Fuel Consumption (‘TSFC’)”—is the industry standard parameter of pound-mass (lbm) of fuel per hour being burned divided by pound-force (lbf) of thrust the engine produces at that minimum point.

“Low fan pressure ratio” is the pressure ratio across the fan blade alone, without a Fan Exit Guide Vane (“FEGV”) system. The low fan pressure ratio as disclosed herein according to one non-limiting embodiment is less than about 1.50. In another nonlimiting embodiment the low fan pressure ratio is less than about 1.45.

“Low corrected fan tip speed” is the actual fan tip speed in ft/sec divided by an industry standard temperature correction of [(Tram ° R)/518.7)^(0.5)]. The “Low corrected fan tip speed,” as disclosed herein according to one non-limiting embodiment, is less than about 1150 ft/second.

The example gas turbine engine includes the fan 42 that comprises in one non-limiting embodiment less than about 26 fan blades. In another non-limiting embodiment, the fan section 22 includes less than about 20 fan blades. Moreover, in one disclosed embodiment the low pressure turbine 46 includes no more than about 6 turbine rotors schematically indicated at 34. In another non-limiting example embodiment the low pressure turbine 46 includes about 3 turbine rotors. A ratio between the number of fan blades 42 and the number of low pressure turbine rotors is between about 3.3 and about 8.6. The example low pressure turbine 46 provides the driving power to rotate the fan section 22 and therefore the relationship between the number of turbine rotors 34 in the low pressure turbine 46 and the number of blades 42 in the fan section 22 disclose an example gas turbine engine 20 with increased power transfer efficiency.

The engine 20 is an example type of turbomachine. Various areas of the engine 20 experience thrust loads when the engine 20 is operating. For example, the low-pressure turbine 46 and the high-pressure turbine 54 apply a turbine thrust load T_(T) to both the low-speed spool 30 and the high-speed spool 32.

The fan section 42 generates a fan thrust load F_(T). The fan thrust load F_(T) and the turbine thrust load T_(T) are applied in axially opposite directions. These loads are essentially decoupled from each other by the geared architecture 48.

At least one of the bearing systems 38 supporting the low-speed spool 30 is a bearing system 38 _(T) that counteracts a thrust load from the low-pressure turbine 46. The bearing system 38 _(T) provides the interface between the rotating rotors of the low-speed spool 30 and the relatively stationary structures of the engine 20.

The example bearing system 38 _(T) interfaces with the shaft 40 of the low-speed spool 30 to counteract the turbine thrust load T_(T). In another example, the bearing system 38 _(T) interfaces with a hub, and extension, or another type of member that rotates with the low-pressure turbine 46.

The bearing system 38 _(T) is an example type of load carrying device. Other Examples of load carrying devices include a tapered roller bearing system, or another type of oil-film bearing with rolling elements. In some examples, the load carrying device may include sliding interface bearings using an oil film. In other examples, the load carrying device can be of a type that uses an air pressure cushion or opposing magnetic forces to provide an effective bearing with no or little oil. The sizing of the example load carrying device 38 _(T) is appropriate for accommodating peak thrust loads of loads greater than 30,000 lbs.

The example bearing system 38 _(T) provides a reaction load R_(L) in a forward direction that counteracts the thrust load T_(T). The reaction load R_(L) may be greater than about 5,000 lbs. (2,268 kg) This level of a reaction load R_(L) may be required when thrust of the engine 20 is at high levels, such as at takeoff. During takeoff of the engine 20 the net load on the bearing system 38 _(T) is in the aft direction.

The example low-pressure turbine 46 includes a rear disk cavity 64 having a pressure that is less than about 20 psi different than a pressure in the gas path 70. These conditions are measured, typically, during a flat-rated, sea level take-off. The example low pressure turbine 46 does not include thrust balancing mechanisms other than the bearing system 38 _(T).

Referring now to FIGS. 2 with continuing reference to FIG. 1, one example of the bearing system 38 _(T) is a ball bearing assembly 78. The ball bearing assembly 78 includes a radially inner race 82 and a radially outer race 84, with ball bearings 90 captured therebetween. The ball bearings 90 are held within a carrier 88 such that the ball bearings 90 are circumferentially spaced from each other. The ball bearings 90 are freely rotatable within apertures 90 of the carrier 88.

In one example, the shaft 40 is held by the inner race 82. The ball bearings 90 permit the shaft 40 and inner race 82 to rotate relative to the outer race 84 while maintaining the axial position of the shaft 40 relative to the outer race 84. The inner race 82 and outer race 84 ride on a thin film of lubricant when moved relative to the ball bearings 90. The outer race 84 can be directly attached to a fixed structure of the engine 20.

The example ball bearing assembly 78 is a thrust ball bearing assembly. The ball bearing assembly 78 counteracts the turbine thrust load T_(T). In this example, a radially outward extending portion 92 of the inner race 82 extends past a radially inner surface 94 of the ball bearings 90. A radially inward extending portion 96 of the outer race 84 extends past a radially outermost surface 98 of the ball bearings 90. The radial overlap between the flanges 92 and 96 and the ball bearings 90 prevents the turbine thrust load T_(T) from moving the shaft 40 axially relative to the outer race 94 during operation.

The ball bearings 90 in this example have a diameter d that is greater than 0.75 in (19.05 mm). The example ball bearing assembly 78 is a thrust ball bearing assembly. Within thrust ball bearing assemblies, ball bearings having this diameter are particularly appropriate for accommodating the peak thrust loads of greater than 30,000 lbs.

Referring to FIGS. 4 and 5 with continuing reference to FIG. 1, another example bearing assembly 38 _(T) is a roller bearing assembly 100. The roller bearing assembly 100 includes a radially inner race 102, a radially outer race 104. A carrier 108 and roller bearings 110 are captured between the inner race 102 and the outer race 104.

Surfaces 112 of the inner race 102 and the outer race 104 interface with the roller bearings 110. These surfaces 112 are segments of cones. The roller bearings 110 have a tapered outer surface 114.

The shaft 40 can be held by the inner race 102. During operation, the tapered outer surface 114 rotates relative to the surfaces 112. The rotating surfaces may ride on a relatively thin film of lubricant rather than directly contact each other. The roller bearings 110 are guided by a flange 116 on the inner race 102 during rotation. The flange 116 stops the roller bearings 110 from sliding axially from between the inner race 102 and outer race 104.

The conical geometry of the surfaces 112 prevents the turbine thrust load T_(T) from moving the shaft 40 axially relative to the outer race 102 during operation. The conical geometry may also facilitate carrying higher loads than ball bearing type designs due to the increased interfacing surface area.

In still other examples, the bearing assembly 38 _(T) may be a single ball bearing design, tapered ball bearing design, spherical thrust bearing design, tapered roller bearing design, or non-tapered roller bearing design.

The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. Thus, the scope of legal protection given to this disclosure can only be determined by studying the following claims. 

We claim:
 1. A turbomachine thrust balancing system, comprising: a member coupled in rotation with a turbine for transferring rotational power therefrom; and a load carrying device rotatably supporting the member, the load carrying device configured to counteract a thrust load generated by the turbine.
 2. The turbomachine thrust balancing system of claim 1, wherein the load carrying device comprises ball bearings.
 3. The turbomachine thrust balancing system of claim 2, wherein the ball bearings have a diameter that is 0.75 inches or greater.
 4. The turbomachine thrust balancing system of claim 1, wherein the load carrying device comprises tapered roller bearings.
 5. The turbomachine thrust balancing system of claim 1, wherein the thrust load is applied rearward relative to a direction of flow through the turbomachine.
 6. The turbomachine thrust balancing system of claim 1, wherein the member is rotatably coupled to a geared architecture of a turbomachine.
 7. The turbomachine thrust balancing system of claim 1, wherein member is a fan drive shaft.
 8. The turbomachine thrust balancing system of claim 1, wherein the load carrying device is configured to counteract a thrust load of more than 30,000 pounds.
 9. A turbomachine comprising: a fan including a plurality of fan blades rotatable about an axis; a turbine section including a fan drive turbine; a geared architecture configured to be rotatably driven by a member that is rotatably driven by the fan drive turbine to rotate the fan about the axis; and a load carrying device supporting rotation of the member and counteracting thrust loads generated by the fan drive turbine.
 10. The turbomachine of claim 9, wherein the load carrying device comprises ball bearings.
 11. The turbomachine of claim 10, wherein the ball bearings have a diameter that is at least 0.75 inches.
 12. The turbomachine of claim 9, wherein the load carrying device comprises tapered roller bearings.
 13. The turbomachine of claim 9, wherein the thrust load is applied rearward relative to a direction of flow through the turbomachine.
 14. The turbomachine of claim 9, wherein the load carrying device is configured to counteract a thrust load of more than 30,000 pounds.
 15. The turbomachine of claim 9, including a rear disk cavity having a pressure that is less than about 20 psi different than a pressure in a gas path of the turbomachine.
 16. A method of balancing thrust loads within a turbomachine, comprising: rotating a member with a turbine; supporting rotation of the member using a load carrying device; driving a geared architecture with the member; and counteracting thrust loads exerted on the member by the turbine using the load carrying device.
 17. The method of claim 16, wherein the load carrying device comprises ball bearings having a diameter that is greater than 0.75 inches.
 18. The method of claim 16, including counteracting thrust loads greater than 30,000 pounds. 